Integrated emboss module

Abstract

The emboss module of the present invention provides for automatic die and bolster conversion. The emboss module includes a frame, a die changer sub-assembly and a bolster sub-assembly. The die changer sub-assembly includes rotatable die changers for automatically registering dies therein, and the bolster sub-assembly includes counters and panels for receiving the sheet of material and the die. Both the die changer and bolster sub-assemblies are adapted for use with emboss and foil dies and counters. Accordingly, a more efficient and scalable emboss system and method for automatically changing dies and bolsters is described herein.

What is claimed:  
     
       1. An emboss module for embossing a sheet of material, comprising: 
       a frame having a scotch yoke and a die changer registration system;  
       a die changer sub-assembly registered into the die changer registration system, wherein the die changer sub-assembly includes die changers, and wherein the die changer sub-assembly further includes a swing arm having die changer receiving ports, wherein each die changer is registered into one die changer receiving port; and  
       a bolster sub-assembly adapted to move within the frame using the scotch yoke.  
     
     
       2. An emboss module according to  claim 1 , wherein the swing arm further includes rollers, wherein each roller is connected to one die changer receiving port. 
     
     
       3. An emboss module according to  claim 2 , wherein each roller is adapted to rotate one die changer receiving port and the die changer registered thereto in a clockwise and counter-clockwise directions. 
     
     
       4. An emboss module according to  claim 3 , wherein each roller is adapted to rotate about 180 degrees. 
     
     
       5. An emboss module according to  claim 1 , wherein each die changer includes a die receiving surface having a plurality of pins extending therefrom. 
     
     
       6. An emboss module according to  claim 5 , wherein each die changer includes heater rods and an insulator. 
     
     
       7. An emboss module according to  claim 1 , wherein each die changer includes cam followers for registering into the frame. 
     
     
       8. An emboss module according to  claim 1 , wherein the bolster sub-assembly includes one or more counters. 
     
     
       9. An emboss module according to  claim 8 , wherein the one or more counters are adapted to receive the sheet of material. 
     
     
       10. An emboss module according to  claim 1  further comprising unwind and rewind stands for providing a foil to be stamped between the die changers and the bolster sub-assembly. 
     
     
       11. Se An emboss module according to  claim 1  further comprising a plurality of pairs of unwind and rewind stands for providing a plurality of different colored foils to be stamped between the die changers and the bolster sub-assembly. 
     
     
       12. An emboss module according to  claim 1  for embossing a sheet of material, comprising: 
       a frame having a scotch yoke and a die changer registration system, wherein the scotch yoke includes a bolster receiving arm, a pair of rails, and a plurality of wheels positioned on the pair of rails  
       a die changer sub-assembly registered into the die changer registration system, wherein the die changer sub-assembly includes die changers; and  
       a bolster sub-assembly adapted to move within the frame using the scotch yoke.  
     
     
       13. An emboss module according to  claim 12 , wherein the bolster receiving arm engages the bolster sub-assembly. 
     
     
       14. An emboss module according to  claim 13 , wherein the bolster receiving arm moves the bolster sub-assembly through the frame using the plurality of wheels on the pair of rails. 
     
     
       15. An emboss module for embossing a sheet of material, comprising: 
       means for a placing a sheet of material on a bolster sub-assembly;  
       means for positioning the bolster sub-assembly within a frame, including means for engaging the bolster sub-assembly with a bolster receiving arm such that the bolster receiving arm moves the bolster sub-assembly through the frame using a plurality of wheels on a pair of rails;  
       means for automatically registering a die on one of a plurality of the die changers;  
       means for positioning the die directly above the sheet of material; and  
       means for pressing the sheet of material on the die, thereby forming an embossment on the sheet of material.  
     
     
       16. An emboss module according to  claim 15 , wherein the bolster sub-assembly includes one or more counters. 
     
     
       17. An emboss module according to  claim 16 , wherein the one or more counters are adapted to receive the sheet of material. 
     
     
       18. An emboss module for embossing a sheet of material, comprising: 
       means for a placing a sheet of material on a bolster sub-assembly;  
       means for positioning the bolster sub-assembly within a frame;  
       means for automatically registering a die on one of a plurality of the die changers, wherein the means for automatically registering the die on one of the die changers comprises means for placing the die on pins of the die changer after the die changer is rotated out of the frame;  
       means for positioning the die directly above the sheet of material; and  
       means for pressing the sheet of material on the die, thereby forming an embossment on the sheet of material.  
     
     
       19. An emboss module according to  claim 18 , wherein the die changer is rotated out of the frame using a swing arm having die changer receiving ports, wherein the die changer is registered into one of the die changer receiving ports. 
     
     
       20. An emboss module according to  claim 19 , wherein the swing arm further includes rollers, wherein each roller is connected to one die changer receiving port. 
     
     
       21. An emboss module according to  claim 20 , wherein each roller is adapted to rotate one die changer receiving port and the die changer registered thereto in clockwise and counter-clockwise directions. 
     
     
       22. An emboss module according to  claim 21 , wherein each roller is adapted to rotate about 180 degrees. 
     
     
       23. An emboss module for embossing a sheet of material, comprising: 
       means for a placing a sheet of material on a bolster sub-assembly;  
       means for positioning the bolster sub-assembly within a frame;  
       means for automatically registering a die on one of a plurality of the die changers, wherein each die changer includes a die receiving surface having a plurality of pins extending therefrom;  
       means for positioning the die directly above the sheet of material; and  
       means for pressing the sheet of material on the die, thereby forming an embossment on the sheet of material.  
     
     
       24. An emboss module for embossing a sheet of material, comprising: 
       means for a placing a sheet of material on a bolster sub-assembly;  
       means for positioning the bolster sub-assembly within a frame;  
       means for automatically registering a die on one of a plurality of the die changers, wherein each die changer includes cam followers for registering into the frame;  
       means for positioning the die directly above the sheet of material; and  
       means for pressing the sheet of material on the die, thereby forming an embossment on the sheet of material.